Fuel feed system for a gasifier and method of gasification system start-up

ABSTRACT

A method of startup for a gasification system includes assembling a fuel mixture for use by a gasifier at a fuel mixture assembly point, wherein the fuel mixture includes a quantity of particulate solid fuel and a quantity of non-ventable carrier gas. The method includes channeling the fuel mixture through a first conduit to a fuel mixture disassembly system including a non-ventable carrier gas removal apparatus, establishing a substantially steady flow of the fuel mixture within the first conduit, and redirecting the fuel mixture through a second conduit to the gasifier to facilitate gasifier startup.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of U.S. application Ser. No. 12/209,711 filed Sep. 12, 2008 and entitled “Fuel Feed System for a Gasifier and Method for Gasification System Start-up” which claims priority to and the benefit of the filing date of U.S. Provisional Application No. 60/982,967 filed on Oct. 26, 2007, the disclosures of which are hereby incorporated herein by reference in their entirety.

BACKGROUND

The field of the disclosure relates generally to gasification, such as gasification used in Integrated Gasification Combined Cycle (IGCC) power generation systems, and more specifically to systems and methods for supplying high moisture content, solid, carbonaceous fuels to gasifiers, and methods of start up for such systems.

At least one known IGCC plant feeds a water-based slurry of bituminous coal to a refractory-lined, entrained flow gasifier to generate the fuel gas used in power generation. Such a slurry feed system may provide an economical and reliable option for feeding higher rank coals, such as bituminous and anthracite coals, to the gasifier. However, such a system is less attractive for lower rank coals, such as sub-bituminous coals, because of the difficulty surrounding the production of low rank coal slurries with a solids concentration and energy content high enough for efficient power production.

Inherent moisture is water trapped in the pores of the coal and therefore such moisture may not be available for making the coal slurry. Low rank coals have a relatively higher inherent moisture content (e.g. 22-30 wt %) compared to high rank coals (e.g. <10 wt %). In known IGCC systems, the production of coal-water slurry is a physical process that includes suspending the coal particles in water to facilitate enabling the coal particles to freely move past one another, i.e. enabling slurry flow within the IGCC system. More specifically, in some known IGCC systems, water may be added in an amount sufficient to produce a slurry with a viscosity no higher than about 700 to 1000 Centipoise to enable the slurries to be screened, pumped and sprayed by the feed injectors. Coals with higher inherent moisture content naturally produce slurries with higher total water content. For example, coals with relatively higher inherent moisture content produce slurries with a lower solids content, i.e. lower energy content per unit volume of slurry. While water may be added to particulate sub-bituminous coal to produce a pumpable slurry, the energy content of the resulting dilute slurry may not reach an energy level capable of sustaining an efficient gasification operation.

In some known IGCC systems, the quantity of water needed to make a pumpable slurry far exceeds the amount of water needed for the reactions. Although some of the water does react with the coal and convert the coal to syngas, most of this excess slurry water passes through the gasifier, consuming some of the thermal energy in the reactor as the water heats up to reaction temperature, and then degrading that thermal energy produced in the gasifier to lower temperature levels as the product gas is cooled in downstream equipment. The extra energy required for heating the excess water to gasifier reaction temperature comes at the expense of burning some of the CO and H₂ in the product syngas to CO₂ and H₂O. This requires additional oxygen to be fed to the gasifier, which decreases efficiency and increases capital cost. Also, by converting some of the CO and H₂ in the product syngas to CO₂ and H₂O in order to heat up the excess water, the amount of CO and H₂ produced per unit of coal gasified decreases. Therefore, in order to fuel the power block with a fixed amount of CO and H₂, the syngas components with fuel value, a larger amount of coal must be gasified when feeding a coal slurry compared with feeding coal in a much drier state. This increased coal requirement both decreases the plant efficiency and increases its capital cost.

Some known combustion turbines must burn a fixed amount of carbon monoxide and hydrogen to achieve their maximum rated power production. To produce the required amount of CO and H₂, a plant feeding a dilute slurry of sub bituminous coal must gasify significantly more coal than a plant feeding a slurry of bituminous coal. Such a sub-bituminous coal plant may be both less efficient and more costly to construct and operate.

Some known IGCC systems feed high moisture content coal to gasifiers using a system known as a dry feed system to overcome the difficulty of producing a high energy content slurry and to avoid the negative impact on overall plant efficiency. In such a dry feed system, lower rank coals may be dried to remove two-thirds, or more, of the inherent moisture present in the coal. The deep drying facilitates improving the flow characteristics of the dried solids in the dry feed system equipment as well as improving the overall efficiency of the gasifier. For instance, high levels of drying are often needed to help reduce the potential consolidation and subsequent flow problems that can result during pressurization of higher moisture content solids in a lock hopper. However, drying the coal may consume a large amount of energy, which reduces the overall power production of the plant as a result. In addition, the dry feed system equipment, which may include a compressor, lock hoppers, lock hopper valves, drying equipment and additional storage capacity, results in a relatively expensive system when compared with slurry-based systems. Furthermore, such systems are limited to relatively modest pressures, on the order of 400 psig or less, because the consumption of gas used for lock hopper pressurization and particle fluidization increases dramatically as system pressures increase.

In some known IGCC systems with slurry fed gasifiers, a two-step process may be used for gasifier startup that includes establishing steady flows of all feeds in bypass and/or startup conduits not connected to the gasifier, and redirecting the flows into feed conduits connected to the gasifier feed injector according to a prescribed sequence. Pre-establishing the flows to the gasifier using this two-step process ensures that the correct fuel-oxidant mixture is delivered to the feed injector which, in turn, assures a substantially safe and reliable startup. The startup slurry flow in a slurry feed system is established in a circulation loop that returns to the original slurry storage tank, and the startup oxygen flow may be vented to atmosphere through a silencer. Upon startup, the slurry and oxygen flows are diverted into the gasifier so that the oxygen reaches the feed injector a short time after the slurry. The thermal energy stored in the preheated gasifier refractory brick ignites the reaction mixture and the gasification reactions begin. In contrast, some known IGCC system use a moist feed (or dry feed) system to feed a gasifier. The fuel in a moist feed system is not a storable material like coal-water slurry. Instead, the fuel is manufactured, or “assembled”, prior to introduction into the gasifier by mixing solid fuel particles into a flowing stream of carrier gas. If this mixture is channeled through a conduit but not consumed in the gasifier, such a stream may not be stored for later use, and the carrier gas—fuel particle mixture must be “disassembled” so that the solid fuel particles can be returned to storage for later use.

Some known moist feed IGCC systems use a two-step startup method in which nitrogen from the air separation unit may be used as a carrier gas during startup operations. During the first step of the startup method when steady flows of all gasifier feeds are established in bypass and/or startup conduits not connected to the gasifier, the nitrogen carrier gas-fuel particle mixture is returned to the original particulate fuel storage bin via one or more gas-solids separation devices. The gas-fuel solids separation devices facilitate removing a high percentage of the nitrogen from the solid particles before returning the solid particles to a storage bin. The nitrogen is subsequently cleaned to remove moisture and very fine particles so that the nitrogen may be reused in the feed system as carrier gas and/or inert blanketing gas. Some of the nitrogen may be vented to the atmosphere as a purge gas which excludes air from the feed system and facilitates maintaining an inert environment within the feed system. Because nitrogen is used throughout the moist feed system, it may not be necessary for the gas-fuel solids separation devices to be 100% efficient in removing nitrogen from the solid fuel particles. Thus, it is generally acceptable to return the unconsumed solid fuel particles to their original storage bin for later reuse.

However, in the case where nitrogen may be unavailable for use as a carrier gas, it may be necessary to use a different carrier gas during startup, such as for example, a process-derived gas such as a sour CO₂-rich gas and/or syngas. In this case, solid fuel particles may not be returned to their original storage bin. The residual process-gas trapped in the pores of the solid fuel particles, along with any process gas entrained by those particles as they return to the storage bin, may contaminate the feed system with a gas that ultimately cannot be vented directly to the atmosphere. In order to use a process-derived gas, i.e. a “non-ventable” gas, as a startup carrier gas a different startup method and process configuration is needed.

SUMMARY

In one aspect, a method of startup for a gasification system is provided. The method includes assembling a fuel mixture for use by a gasifier at a fuel mixture assembly point, wherein the fuel mixture includes a quantity of particulate solid fuel and a quantity of non-ventable carrier gas. The method includes channeling the fuel mixture through a first conduit to a fuel mixture disassembly system including a non-ventable carrier gas removal apparatus, establishing a substantially steady flow of the fuel mixture within the first conduit, and redirecting the fuel mixture through a second conduit to the gasifier to facilitate gasifier startup.

In another aspect, a gasification system is provided. The gasification system includes a gasifier, a fuel mixture for use by the gasifier, wherein the fuel mixture includes a quantity of particulate solid fuel and a quantity of non-ventable carrier gas. The system includes a pressurization and conveyance section coupled in flow communication upstream from the gasifier, wherein the pressurization and conveyance section includes a fuel mixture disassembly system that includes a non-ventable carrier gas removal apparatus configured to strip the quantity of non-ventable carrier gas from the fuel mixture.

In yet another aspect, a fuel feed system for use in a gasification system is provided. The fuel feed system includes a pressurization and conveyance section coupled in flow communication upstream from the gasifier, wherein the pressurization and conveyance section includes a fuel mixture disassembly system including a non-ventable carrier gas removal apparatus configured to strip a quantity of non-ventable carrier gas from a quantity of particulate solid fuel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a portion of an exemplary IGCC power generation plant that includes an exemplary fuel system.

FIG. 2 is a process flow diagram of an exemplary feed preparation system used with fuel system shown in FIG. 1.

FIG. 3 is a process flow diagram of an exemplary feed pressurization and conveyance system used with the fuel system shown in FIG. 1.

FIG. 4 is a process flow diagram of an exemplary slag additive system used with the fuel system shown in FIG. 1.

FIG. 5 is a process flow diagram of an alternative startup configuration used with the pressurization and conveyance section shown in FIG. 3.

FIG. 6 is a process flow diagram of an alternative startup configuration used with the pressurization and conveyance section shown in FIG. 3.

FIG. 7 is a process flow diagram of an alternative startup configuration used with the pressurization and conveyance section shown in FIG. 3.

DETAILED DESCRIPTION

FIG. 1 is a block diagram of a portion of exemplary IGCC power generation plant 50. In the exemplary embodiment, plant 50 includes a fuel feed system 110, an air separation unit 112 coupled in flow communication with fuel feed system 110, a gasification plant 114 coupled in flow communication with feed system 110, and a power block 116 coupled in flow communication with gasification plant 114 and IGCC power generation plant 50. During operation, air separation unit 112 uses compressed air to generate oxygen for use by gasification plant 114. More specifically, air separation unit 112 separates compressed air received from an external source (not shown) into separate flows of oxygen and a gas by-product, typically nitrogen. In the exemplary embodiment, gasification plant 114 converts solid fuel and oxygen into a clean fuel gas that is burned in power block 116 to produce electrical power, as will be described in more detail herein. It will be clear to those skilled in the art that this diagram is a simplified version of an IGCC power plant block flow diagram and that, for the sake of clarity in explanation, not all of the equipment blocks nor all of the connecting lines found in such a power plant have been shown in the diagram.

A solid carbonaceous fuel (not shown) is channeled into a feed preparation section 118 of feed system 110 via a conduit 120. In the exemplary embodiment, the solid carbonaceous fuel is coal. Alternatively, the fuel may be a petroleum coke, a biomass, or any other solid carbonaceous fuel that will enable IGCC power plant 50 to function as described herein. In another embodiment, a slag additive may be introduced with the solid fuel within conduit 120. Feed preparation section 118 converts the as-received fuel into a solid particulate gasifier feed with a target particle size distribution and internal moisture content suitable for use in IGCC plant 50. Low pressure nitrogen from air separation unit 112 enters feed preparation section 118 via conduit 122, a portion of which is used to convey the solid particulate feed material to a pressurization and conveyance section 124 via conduit 126. The remaining portion of the low pressure nitrogen is heated in feed preparation section 118 and channeled via conduit 128 to pressurization and conveyance section 124 for use in moisture and fines control within section 124. Low pressure nitrogen used in the pressurization and conveyance section 124 is channeled back to feed preparation section 118 via conduit 130 to be filtered, which facilitates removing particulate fines, and is then dried to facilitate removing substantially all water therein, so that the low pressure nitrogen may be reused for various purposes throughout feed system 110. As an alternate to low pressure nitrogen, any gas can be used that allows for the safe and reliable conveyance of the coal in accordance with the feed system described herein. In an alternative configuration, any particle size reduction, control and drying system may be used that reasonably produces the correct particle size and moisture content coal in accordance with the feed system described herein.

In the exemplary embodiment, gasification plant 114 includes an acid gas removal section 132 coupled in flow communication with a gasifier 134. Acid gases, such as H₂S COS and CO₂, are removed from a quantity of raw syngas to produce a clean fuel gas that is channeled to a combustor 136 located in power block 116 via conduit 138 for producing electrical power, as described in more detail herein. Acid gas removal section 132 produces a byproduct sulfur stream 140 and a sour, CO₂-rich gas stream 142 that is compressed and recycled to feed system 110 and that is used as the high pressure conveying gas for transporting the solid particulate fuel into gasifier 134. The CO₂ recovered from the syngas within acid gas removal section 132 is compressed and channeled to feed preparation section 118 via conduit 142. This recycled CO₂-rich gas stream is heated within feed preparation section 118 and then channeled via conduit 144 to pressurization and conveyance section 124 for use as the high pressure pneumatic conveying gas that transports the particulate solid fuel into gasifier 134 via feed conduit 146. In the exemplary embodiment, high pressure nitrogen from air separation unit 112 is channeled to feed preparation section 118 via conduit 148. In the preferred embodiment, this nitrogen stream, is only used during startup when recycled CO₂-rich gas is not yet available (as described in more detail herein), is preheated and then channeled via conduit 144 to pressurization and conveyance section 124 for use as a high pressure pneumatic conveying gas during gasifier startup. Alternatively, any high pressure gas is used during startup that allows for the safe and reliable operation of the gasification system as disclosed herein. Further alternatively, any high pressure gas is used during normal operation that allows for the safe and reliable operation of the gasification system as disclosed herein.

In the exemplary embodiment, feed system 110 includes a slag additive handling section 152 that receives a slurry of char (i.e. unconverted solid particulate fuel) and fine slag via conduit 154 from a char and fines handling section 156. This fine particulate material is recovered as a dilute aqueous slurry from gasification plant 114. The char fraction of this slurry is the unconverted carbon from gasifier 134, and is subsequently recycled via conduit 154. Slag or mineral additive is channeled from an externally located storage section (not shown) to slag additive handling section 152 via conduit 158. The mineral additive is pulverized in a dry rod or ball mill (not shown in FIG. 1) and mixed with the char and fine slag slurry to make a final additive slurry that is channeled by a positive displacement pump (not shown) into gasifier via conduit 160. In an alternative embodiment, a secondary water stream 162 may be used to add water to the final additive slurry fed to gasifier 134 to control temperatures and modify reaction chemistry. In a further alternative embodiment, the mineral additive is fed as dry solids to gasifier 134, in a mixture with the dry particulate fuel or using a separate feed system with a dry solids pump and conveying gas. In a still further alternative embodiment, the mineral matter is fed to gasifier 134 as a separate slurry, separate from the recycle solids slurry. In yet another alternative embodiment, the mineral matter is procured as a preground additive and blended with the recycle solids slurry. In an even further embodiment, the mineral additive is any mineral-containing material that facilitates the operation of the gasification system as described herein. Alternatively, no mineral additive is used and only a quantity of recycled char and fines, or liquid water alone is channeled to gasifier 134 via a separate conduit 165.

During operation, air separation unit 112 separates oxygen from air to produce a relatively high purity (about 95% by volume O₂) oxygen feed for use within gasifier 134. A first portion of air enters the air separation unit 112 directly via conduit 164. A remaining portion of air is extracted from the combustion turbine air compressor 196 conduit 166. In the exemplary embodiment, the first portion of air is about 50% of the total quantity of incoming air. Alternatively, the first portion of air may be any percentage of the total quantity of air that enables fuel feed system 110 to function as described herein. In addition to producing the gasifier oxygen feed, air separation unit 112 also produces nitrogen for use within feed system 110. The remaining nitrogen rich byproduct gas is returned via conduit 168 to the combustion turbine 192 for use as a diluent gas by combustor 136.

In the exemplary embodiment, feeds channeled to gasification plant 114 include pneumatically conveyed particulate solid fuel via conduit 146, slag additive, char and fine slag slurry via conduit 160, and high purity oxygen from air separation unit 112 via conduit 170. During operation, gasifier 134 converts the feeds into raw syngas that is subsequently channeled to acid gas removal section 132 via conduit 172. A coarse slag (not shown) that is separated from the syngas within gasification plant 114 is recovered as a byproduct slag stream 174. Any unconverted carbon is recovered along with fine slag as a dilute slurry and channeled via conduit 176 to handling section 156. High pressure steam generated by the cooling of the hot syngas effluent from gasifier 134 is channeled via conduit 178 to power block 116 wherein the high pressure steam is expanded through a steam turbine 180 to produce electrical power. In the exemplary embodiment, a process water stream (not shown) is channeled as a dilute slurry 182 to a treating section 184 that treats the water to control the concentrations of various contaminants in the circulating process water system, including but not limited to dissolved and suspended solids, and subsequently returns the treated water stream to gasifier 134 for reuse via conduit 186. A clean stream of water (not shown) is channeled from treating section 184 via conduit 188 to disposal or beneficial use beyond the plant boundary. A dilute slurry (not shown) of fine solids removed from the water stream during cleaning is channeled via conduit 190 to handling section 156. In an alternative embodiment, the char and fines are not recycled to the gasifier or are only partially recycled to the gasifier. Instead, the portion of char and fines not recycled to the gasifier is channeled from char and fines handling system 156 via a separate conduit, not shown, to disposal or beneficial use. In a further embodiment, all or a portion of the char and fines are dried before recycle to the gasifier and fed to the gasifier in combination with the coal, in combination with the dry slag additive or as a separate stream. In a still further alternative, the char and fines are recovered from the gasification system using dry scrubbing technology, and all or a portion are recycled to the gasifier in combination with the coal, in combination with the dry slag additive or as a separate stream.

In the exemplary embodiment, power block 116 includes a combustion turbine 192 and a steam system 194. Combustion turbine 192 includes an air compressor 196 operatively coupled to a power expansion turbine 198 and an electrical power generator 200 via a single shaft 202. During operation, the combustion turbine 192 produces power by burning clean fuel gas 138 using, for example, a Brayton Cycle, and steam system 194 produces power by expanding steam through a steam turbine 180 using, for example, a Rankine Cycle. More specifically, clean fuel gas 138 from compressor 196 and diluent nitrogen 168 (used to control NO_(x) formation) are channeled to combustor 136 and mixed and combusted therein, wherein the exhaust gaseous products of combustion are expanded through expansion turbine 198, thereby turning shaft 202, which in turn operates compressor 196 and generator 200 and electrical power is produced therein. Hot exhaust gas from expansion turbine 198 is channeled through a heat recovery steam generator (HRSG) 204. A high pressure steam generated as the hot exhaust gas cools is combined with high pressure steam 178 generated in syngas cooling section of gasification plant 114, then superheated in the HRSG 204, recovering additional energy from the hot exhaust gas, and is then channeled to steam turbine 180 where it is expanded to make additional electrical power via generator 206. The expanded steam is then condensed within a condenser 208 to produce boiler feed water, which is subsequently channeled to HRSG 204 and the syngas cooler in the gasification plant 114.

FIG. 2 is a process flow diagram of an exemplary feed preparation system 118 used with fuel feed system 110 shown in FIG. 1. More specifically, FIG. 2 illustrates five flow configurations that may be used with fuel feed system 110. In the exemplary embodiment, a volume of sub-bituminous coal, for example Powder River Basin (PRB) coal, not shown, is channeled to feed preparation section 118 via conduit 120 and is conveyed through an air stripping tube 210 wherein the volume of coal is contacted by a counter-current flow of low pressure nitrogen 212 being channeled thereto from a nitrogen storage drum 214. Low pressure nitrogen 212 strips residual air from the interstitial spaces between the incoming pieces of coal. In the exemplary embodiment, the coal is maintained in a nitrogen-rich atmosphere in all equipment operatively coupled downstream from tube 210. Alternatively, any suitable inerting gas, such as CO₂ or vitiated air, may be used to maintain coal in a low oxygen-content environment. The nitrogen and associated particulate matter exiting air stripping tube 210 is filtered in a dust control unit 216 prior to being exhausted to the atmosphere. This exhaust valve point is a main loss point for low pressure nitrogen from system 110, and the flow of nitrogen exhausting through dust control unit 216 is the major factor determining the makeup rate 218 from air separation unit 112 (shown in FIG. 1). In the exemplary embodiment, air stripping tube 210 includes a plurality of downwardly sloping baffle plates (not shown) positioned within air stripping tube 210 to facilitate creating a counter-current of nitrogen and particles within tube 210. In an alternate embodiment, air stripping tube 210 may be a featureless column. In another alternate embodiment, air stripping tube 210 may be any configuration that facilitates the stripping of air from the coal in the fuel system disclosed herein, including configurations involving purged air locks. In an alternate embodiment, an air stripping tube 210 may not be used, but instead oxygen concentrations are controlled to safe levels by introducing inert gases at one or more points in the feed preparation system, including but not limited to CO₂ as the result of combusting a fuel.

Coal drops through air stripping tube 210 onto a weigh belt feeder 220 that is operatively coupled downstream from tube 210 and that is used to meter the coal into a cage mill 222. In the exemplary embodiment, cage mill 222 grinds the coal to a desired particle distribution in a single step. Alternatively, a two-step grinding process (not shown) may be used that utilizes a hammer mill followed by a cage mill. In the exemplary embodiment, a target particle size distribution for the coal is about 50% to about 80% filtered through a 100 mesh screen and about 100% filtered through a 10 mesh screen. Alternatively, any appropriate grinding equipment may be used in light of the type of coal feed within fuel feed system 110, and that enables fuel feed system 110 to function as described herein.

In the exemplary embodiment, a low pressure nitrogen gas or other suitably inert gas purge stream 224 maintains a supply of gas purge on the grinding equipment to prevent buildup of coal fines and to remove moisture liberated from the coal by the cleaving of coal particles and evaporated from the coal by the heat of grinding. Purge stream 224 is combined with spent purges from other parts of the system, and the combined stream is channeled through dust filter 226, compressed in blower 228 and channeled to inert gas drying package 230. Filter 226 facilitates substantially removing fine coal dust from the purge stream 224, and drying package 230 substantially removes all moisture from the purge stream 224. Inert gas is then recycled to storage drum 214 for reuse within system 110, and condensed water from the inert gas drying package 230 is recycled for use elsewhere in the plant or routed to an externally located wastewater treatment unit (not shown). In an alternative embodiment, condensed water from inert gas drying package 230 may be recycled (not shown) for use elsewhere in gasification system 50, such as but not limited to the additive slurry tank 406, described later. In another alternative embodiment, inert gas drying package 230 is not used to substantially dry the inert gas, but is an inert gas humidity and temperature control unit that adjusts the humidity and temperature of the inert gas as needed to help maintain the coal within fuel feed system 110 at a desired moisture level content.

In the exemplary embodiment and in one exemplary flow configuration (1), ground coal particles are channeled via conduits 232, 234 and 236 into an inlet 238 of a main coal storage silo 240. In the exemplary embodiment, silo 240, and conduits 232, 234 and 236 are insulated to substantially prevent cooling of the coal and condensing of any moisture liberated by the grinding process. A stream of low pressure nitrogen or other inert gas 242 is channeled from drum 214 and enters a purge gas inlet 244 in storage silo 240. During operation, the nitrogen or inert gas flow 242 may be used to fluidize a lower portion 246 of storage silo 240 to enable the solids to flow of out of silo 240. It also maintains a sufficiently inert environment throughout silo 240 to substantially prevent spontaneous combustion therein. And as it rises upwards through silo 240, the nitrogen or inert gas flow 242 strips away any excess, residual moisture from the coal solids that may have been liberated during the grinding process and thus substantially prevents moisture from re-condensing as the coal particles cool.

In the exemplary embodiment, coal is channeled from an outlet 248 positioned on the bottom 246 of storage silo 240 and is metered into a pneumatic pick-up station 250 where the coal is entrained in a flow of low pressure nitrogen gas 252 channeled from the drum 214. The nitrogen or other inert gas 252 transports the coal particles via dense phase pneumatic transport in conduit 126 to feed pressurization and conveyance system 124 (shown in FIG. 1). In an alternative embodiment, the coal particles may be transported by any means that facilitates the operation of the fuel feed system 110 as described herein.

In the exemplary embodiment, feed preparation section 118 includes equipment for heating gas used in conveying coal and for reducing moisture therein. More specifically, low pressure nitrogen or other inert gas from drum 214 is heated in a low pressure coil 256 of a natural gas-fired heater 258. Alternatively, a conduit 260 is configured to bypass coil 256 and is used to adjust the final temperature of the heated nitrogen 262. This heated low pressure nitrogen or other inert gas stream 262 is used for conveying and moisture removal in some of the other flow configurations shown on FIG. 2 as well as in downstream equipment, as described in more detail herein. Heater 256 includes a high pressure gas heating coil 264 that increases a temperature of a high pressure conveying gas (not shown) for use in the feed pressurization and conveying section 124 (shown in FIG. 1). In the exemplary embodiment, the high pressure conveying gas is recycled sour CO₂ 266. Alternatively, the high pressure conveying gas may be high pressure nitrogen 268 channeled thereto from air separation unit 112, or the high pressure conveying gas may be natural gas channeled thereto from an external source (not shown). As another alternative, the high pressure conveying gas may be any gas suitable for conveying the coal within fuel feed system 110 and into the gasifier 134. In a further alternative, fired heater 256 is replaced by other heating means, including, but not limited to, direct heating by the combustion of air and natural gas or indirect heating by heat exchange with steam or other hot process gases available from elsewhere in IGCC plant 50.

In an alternative embodiment and in the second exemplary flow configuration (2), a steam-jacketed paddle dryer 270 is coupled in flow communication between the cage mill 222 and main storage silo 240. Paddle dryer 270 is purged with low pressure nitrogen or inert gas stream 272 to remove moisture liberated during the coal drying process. Moisture-laden nitrogen or inert gas 274 then combines with nitrogen or inert gas from cage mill 222 and is processed to remove coal dust and water vapor, as described in more detail herein. Paddle dryer 270 may be incorporated into feed preparation system 118 when a higher degree of moisture removal from the coal particles is desired, or when the feed coal requires additional drying to remove surface moisture. Alternatively, the coal may be dried using other drying methods that facilitate operation of the fuel feed system as described herein.

In another alternative embodiment and in the third exemplary flow configuration (3), coal is channeled through air stripping tube 210 onto a weigh belt feeder 220 and is channeled via conduit 275 through a chute 276 into a pulverizer 278, e.g. a bowl mill. In the exemplary embodiment, pulverizer 278 is a roller mill. Alternatively, pulverizer 278 may be a bowl mill or a ball mill or any such device used to grind coal to a target particle size including equipment for associated drying requirements, and that enables fuel feed system 110 to function as described herein. Low pressure nitrogen or other inert gas, heated within heater 258 or other heating means not shown, is channeled via conduit 280 to a pulverizer inlet 282 along with coal, where it substantially dries the coal particles to the target moisture level as the coal is being pulverized. For example, the final coal moisture level can be controlled by adjusting the temperature of stream 282. Other control methods include controlling the humidity and flow rate of the warm nitrogen or other inert gas. The warm nitrogen or other inert gas carries the dried coal particles out of the pulverizer 278 and transports them via conduit 126 to feed pressurization and conveyance section 124 (shown in FIG. 1).

In another alternative embodiment and in the fourth exemplary flow configuration (4), an additional grinding mill 222 is coupled in flow communication between weigh belt feeder 220 and pulverizer 278. In this embodiment, grinding mill 222 may be a hammer mill or other suitable mill when coupled in conjunction with pulverizer 278 that produces the desired particle size distribution. Coal from the weigh belt feeder 220 is crushed or pre-ground in a first step in mill 222 and then is channeled via conduits 284 and 286 to pulverizer 278.

In another alternative embodiment and in the fifth exemplary flow configuration (5), coal is channeled from air purge tube 210 onto weigh belt feeder 220 and is directed into cage mill 222 for grinding. The ground coal is then channeled past paddle dryer via conduit 232 and is channeled via insulated conduit 234 to pneumatic transport pickup point 286. At this point, hot, dry, low pressure nitrogen or other inert conveying gas 288 from heater 258 entrains the ground coal particles and channels the ground coal in dense phase transport via insulated conduit 290 into a cyclone 292. Alternatively, the coal particles may be transported by any means that facilitates the operation of the fuel feed system as described herein. The temperature of the hot conveying gas and the length of the insulated transport conduit 290 is such that, when combined with the heat of grinding from cage mill 222, both surface moisture and a portion of the moisture internal to the pores of the coal particles is vaporized and driven into the bulk gas phase. The amount of vaporization is controlled by adjusting the temperature, flow rate and humidity of stream 288.

In the fifth flow configuration, the particulate solids are separated from the conveying gas in cyclone 292 and drop into a moisture stripping column 294. In this embodiment, moisture stripping column 294 includes a plurality of downwardly sloping baffle plates (not shown) positioned within moisture stripping column 294 to facilitate creating a counter-current of nitrogen or other inert gas and particles therein. Alternatively, moisture stripping column 294 may be a featureless column. The particles then encounter a second, upwardly flowing stream 296 of hot, dry nitrogen or other inert gas from heater 258 therein. This stripping gas stream 296, which flows counter-current to the downwardly flowing coal particles, strips away residual moisture from the interstitial spaces between coal particles that was liberated during the grinding but that was not removed within the cyclone 292. Hot, dry coal particles exit stripping column 294 and enter silo 240 at inlet 238. The coal is channeled via dense phase pneumatic transport within conduit 126 to the feed pressurization and conveyance section 124 (shown in FIG. 1) as described in more detail herein. Moreover, finely ground coal within an overhead flow 299 from cyclone 292 is channeled through a secondary cyclone 300 that returns the coal fines back to stripping column 294 via a conduit 302 to an inlet 304. Excess gas from secondary cyclone 300 is channeled to dust collection system 226 where, along with the other purges from the system, the combined gas is filtered to remove substantially all remaining coal dust. After compression by blower 228, the gas is channeled to gas dryer 230 for removal of substantially all of the residual moisture that was present as a result of grinding and drying the coal. The dry, particle free nitrogen or other inert gas exits dryer 230 and may then be recycled to drum 214 for reuse throughout the fuel feed system 110.

FIG. 3 is a process flow diagram of an exemplary feed pressurization and conveyance system 124 used with the fuel feed system 110 shown in FIG. 1. Particulate solids with the desired size distribution and moisture content are conveyed from feed preparation section 122 (shown in FIG. 1) via dense phase pneumatic transport in conduit 126, as described in more detail herein. A storage bin primary inlet cyclone 320 separates solids from the low pressure nitrogen or other inert transport gas and discharges the solids to an inlet 322 of a storage bin inlet stripping tube 324 for further processing. Overhead gas from cyclone 320 is then channeled via conduit 326 through a storage bin secondary inlet cyclone 328 that removes a substantial portion of entrained coal fines from the transport gas and channels the coal fines via conduit 330 to the inlet 322 of stripping tube 324. Secondary cyclone 330 overhead gas is channeled via conduit 332 to a dust control system 334. The substantially dust-free gas is then compressed by a blower 336 and channeled to a nitrogen drying package 230 (shown in FIG. 2) for reuse throughout fuel feed system 110. Alternatively, drying package may be a temperature and humidity control package.

The coal particles removed by cyclones 320 and 330 enter inlet 322 and are channeled downwards against a counter-current flow of heated nitrogen or other inert stripping gas 128. In this embodiment, stripping tube 324 includes a plurality of downwardly sloping baffle plates (not shown) positioned within stripping tube 324 to facilitate creating a counter-current of nitrogen and particles therein. Alternatively, stripping tube 324 may be a featureless column. The stripping gas removes residual moisture that may remain following grinding and drying, as is described in more detail herein. After passing through stripping tube 324, the coal particles enter a storage device, such as for example, solids pump storage bin 338.

In the exemplary embodiment, storage bin 338 is configured to provide coal feed to two solids pumps 340 that operate in parallel. Alternatively, storage bin 338 may be configured to feed any number of solids pumps 340. As a further alternative, fuel feed system 110 can be configured to have any number of storage bins 338 and solids pumps 340 that facilitate the operation of the fuel feed system as described herein. In the exemplary embodiment, solids pump 340 is a rotary, converging space Solids Transport and Metering pump utilizing Stamet™ Posimetric® feed technology, otherwise known as a Stamet™ solids pump commercially available from GE Energy, Atlanta, Ga. This pump is capable of transporting solids from atmospheric pressure to pressures well over 1000 psig with a strongly linear relationship between pump rotational speed and solids mass flow. Alternatively, any type of pump or pressurizing conveyance device may be used that handles and pressurizes solids as described herein.

In the exemplary embodiment, a suction feed vessel 342 is coupled in flow communication between each outlet conduit 344 from storage bin 338 and each solids pump 340, wherein each suction feed vessel 342 controls the flow of coal to each solids pump 340. More specifically, each feed vessel 342, which is designed to withstand full gasifier system pressure, includes an inlet safety valve 346 that is closed in the event of a pump failure. Alternatively, or in cooperation with inlet safety valve 346, additional outlet safety valves, not shown, may be located in the discharge line 352 of each solids pump. In the exemplary embodiment, feed vessels 342 are live-bottom vessels configured to ensure that the suction inlet of each respective solids pump 340 is filled with coal thereby ensuring a continuous a flow of particulate solids through each pump. Alternatively, lines 344 are designed to provide a buffer volume, and may incorporate inlet safety valves 346 and other features, such as but not limited to contoured and vibratory surfaces to assist with the flow of solids into the inlet of pumps 340.

In the exemplary embodiment, particulate solid fuel from suction feed vessels 342 is pressurized by solids pumps 340 to a pressure level sufficient to enable the solids to flow through feed injector 348 and into the gasifier 134 (not shown in FIG. 1). A high pressure stream of nitrogen 350 from the air separation unit 112 (shown in FIG. 1), which may or may not be preheated, is coupled to a discharge conduit 352 of each solids pump 340 at two locations, a first connection 354 located adjacent the discharge 356 of solids pump 340, and a second connection 358 positioned downstream from first connection 354. First connection 354 provides a flow of seal nitrogen that traverses backwards through the compacted solid particles moving through solids pump 340. Although gas leakage backwards through solids pump 340 is minimal, the seal nitrogen prevents leakage of conveying gas, oxygen or syngas backwards through the pump. Second connection 358 provides a relatively higher velocity jet of nitrogen directed at the particulate solids emerging from the solids pump discharge 356. The high speed jet breaks up occasional agglomerations of particles and provides a substantially even distribution of the particulate fuel that exits the solids pump 340 and further enables the solids to transition from the highly compacted condition inside the pump to the free flowing fluidized condition required for high pressure pneumatic transport downstream of solids pumps 340. In the preferred embodiment, the high pressure pneumatic transport of coal downstream of the solids pump 340 is dilute phase transport. Alternatively, the high pressure pneumatic transport of coal downstream of solids pump 340 is of any type that facilitates operation of the fuel and gasification systems. As an alternative to the high speed jet, any mechanical delumping device may be used at any point on conduit 352 that will enable fuel feed system 110 to function as described herein. Alternatively, the seal nitrogen described herein may be any clean, inert gas that enables the fuel and gasification systems to function as described herein.

In the exemplary embodiment, following the delumping operation, the coal particles are channeled via discharge conduit 352 into a pneumatic transport conduit 360. Therein, a high pressure conveying gas 362 from heater 258 (shown in FIG. 2) entrains the coal solids via dilute phase pneumatic conveyance directly to the gasifier feed injector 348 via conduits 364, 366 and 380. Solids flow control herein is achieved by varying the speed of operation of solids pumps 340 and/or the flow, pressure and temperature of the high pressure conveyance gas. In an alternate embodiment, the high pressure carrier gas is not heated. In a further alternate embodiment, the high pressure carrier gas is processed any way that facilitates operation of the fuel and gasification systems as described herein.

In an alternative embodiment, the solids are channeled via conduit 368 into a high pressure feed vessel 370 that serves as a buffer in the conduit between solids pumps 340 and gasifier feed injector 348. During operation, feed vessel 370 is an alternative flow path that may be used to improve solids flow to gasifier 134 (not shown in FIG. 1). Feed vessel 370 may help minimize the effects of temporary flow variations or interruptions at the solids pumps 340, or in the alternative embodiment where solids pumps 340 are not Posimetric pumps that may not have the same or substantially the same continuous flow characteristics as the Posimetric technology described herein.

During operation of feed vessel 370, and in one embodiment, a portion of a high pressure conveying gas is diverted via conduit 324 from the solids transports conduit 360 and channeled via conduit 372 to a bottom portion 376 of the feed vessel 370 to fluidize the solids and enhance flow characteristics thereof. A remainder 378 of the high pressure conveying gas is used to channel the solids out of feed vessel 370 and into conduits 366 and 380 towards feed injector 348. In this embodiment, flow control is achieved by adjusting the operational speed of solids pumps 340 and by adjusting the flow rates of the high pressure conveying gas streams 372 and 378 that are channeled to the bottom 376 of feed vessel 370.

In another alternative embodiment, it may be necessary to recycle more sour CO₂ gas to the gasifier 134 (shown in FIG. 1) than is needed to convey the solids or that can be handled by the solids conveyance conduits. In this embodiment, an additional conduit 382 and 384 is available for feeding gas directly to the feed injector 348. This additional volume of gas may be used to moderate the temperature within gasifier 134 (not shown in FIG. 3), to modify the spray characteristics of the feed injector 348, or to modify the chemistry of the gasification reactions.

FIG. 4 is a process flow diagram of an exemplary slag additive handling section 152 used with the fuel feed system 110 shown in FIG. 1. In the exemplary embodiment, slag additive handling section 152 includes a slag additive mill 402, such as a rod mill or ball mill, that receives a quantity of slag additive (not shown) from an externally located source (not shown) via a slag additive weight belt feeder 404. A slag additive/recycle fines mix tank 406 is coupled downstream and in flow communication from mill 402. More specifically, slag additive is ground to the target particle size distribution within mill 402, which, in the exemplary embodiment, operates in a dry mode. Alternatively, any type of mill that facilitates operation of the fuel system described herein may be used. Fugitive emissions from mill 402 are captured in a dust collection system 408. In an alternative embodiment, the slag additive is received as pre-ground material, eliminating a need for mill 402.

In the exemplary embodiment, char and fines slurry is channeled via conduit 154 from handling section 156 (shown in FIG. 1) into the mix tank. Dry particulate additive from the mill 402 is mixed with the char and fines slurry within mix tank 406 by an agitator 410. A plurality of conduits 412 and 414 form a continuous loop 416 through which a mix tank pump 418 circulates slag additive/recycle fines slurry past the suction of charge pump 420 to ensure that the charge pump always has an adequate supply of slurry and to provide additional mixing in tank 406. Slurry is withdrawn from the suction recirculation loop 416 into charge pump 420 positioned downstream from mix tank pump 406. In the exemplary embodiment, charge pump 420 is a high pressure positive displacement pump that feeds the slurry via conduit 422 to gasifier feed injector 348 (shown in FIG. 3). Once the moisture level of the solid fuel being channeled to gasifier 134 (shown in FIG. 1) has been set by the operation of the feed preparation section 118, the final, total amount of water fed to gasifier 134 can be controlled by adjusting the slurry concentration of the char and fines slurry and/or the amount of fresh water makeup 424 added to mix tank 406. Alternatively, the slag additive may be ground together with the recycle solids in a wet rod or ball mill rather than grinding the slag additive separately and then blending it with the recycle solids. The product from such a co-grinding operation is screened and then sent to mix tank 406. In an alternative embodiment, the total amount of water fed to gasifier 134 may be controlled by injecting any additional required water into the recycle solids slurry downstream of charge pump 420, or as a separate feed to the gasifier 134.

Referring now to FIG. 1, and in the exemplary embodiment, prior to ignition of combustion turbine 192 and start up of gasifier 134, another carrier gas source must be provided until sufficient levels of CO₂ are produced by gasifier 134 and can be recovered to maintain a running fuel feed system 110. This secondary carrier gas may by necessary because typically CO₂ cannot be recovered from the syngas until the gasifier starts, or, in the case of a multi-train gasification operation, there may not be sufficient CO₂ available to provide the required amount of CO₂ to the operating trains as well as the train undergoing startup. In the exemplary IGCC plant 50, high pressure nitrogen obtained from the air separation unit 112 is not needed as a clean fuel gas diluent for clean fuel gas 138 until after gasifier 134 has been started and syngas is produced therein. In an alternative embodiment where the gasifier is integrated into an ammonia production plant rather than an IGCC plant, the nitrogen from the air separation unit may not be needed for ammonia synthesis until after the gasifier is started and syngas is produced.

Drum 214 is filled with low pressure nitrogen from the air separation unit 112 or from on-site storage, not shown. Coal is introduced into inlet air purge tube 210 (shown in FIG. 2) and is subsequently ground in cage mill 222, as described herein, and loaded into main coal silo 240 wherein moisture by grinding is purged out by nitrogen 242. Low pressure conveying gas 252 from drum 314 entrains the coal from silo 240 to storage bin 338, as shown in FIGS. 2 and 3. Once bin 338 is loaded, high pressure nitrogen from the air separation unit 112 is heated in heater 258 and a continuous flow thereof is channeled to cyclone 386 (shown in FIG. 3) via successive conduits 144, 362, 360, 364, 366, 388 and 390. Nitrogen is channeled from cyclone 386 through the high efficiency cyclone package 392, the dust collection system 334, blower 336, the N₂ dryer 230 and exhausted through a vent 394 in drum 214. Once the N₂ conveying gas flow has been established at the correct rate, solids pumps 340 are started and pressurized solids are channeled to the conveying gas transport conduit 360. The dilute phase flow of solids is direct through conduits 364, 366, 386, 388 and 390 to cyclone 386. The cyclone 386 sends the solids back into the solids pump storage bin 338, and the nitrogen passes through nitrogen return system to drum 214. This off-line operation allows the gas and solids flows to be adjusted to their correct flow rates before introduction to the gasifier.

In the exemplary embodiment, a flow rate for the slag additive/char and fines slurry is also established. Referring again to FIG. 4, and in the exemplary embodiment, initially there is no recycle char and fines slurry available into which the particulate slag additive may be mixed. Rather, a startup mixture of slag additive is produced with fresh water in mix tank 406. Slurry circulation pump 418 continuously circulates the startup slurry past the suction of the charge pump 420, and charge pump 420 circulates pressurized slurry through conduit 428 back to the mix tank 406. This circulation allows the correct flow rate for the additive slurry to be established off-line prior to startup of gasifier 134.

Following the establishment and stabilization of flow rates for additive slurry, pneumatically-conveyed coal solids and oxygen, a block valve 426 on conduit 428 closes substantially concurrently with the opening of a block valve 430 on conduit 422, and thus slurry is transferred to gasifier feed injector 348 instead of being recirculated back into mix tank 406. In the exemplary embodiment, substantially concurrently therewith, block valve 394 on conduit 390 closes and a block valve 396 on conduit 380 substantially concurrently opens. N₂-conveyed solids therein are transferred to the gasifier feed injector 348. When oxygen is subsequently introduced to gasifier 134, the thermal energy stored in the gasifier 134 initiates the reactions, and syngas generation begins. As syngas is channeled downstream from gasifier 134, CO₂ recovery begins, and the CO₂ stream is compressed and recycled to the front end of the fuel feed system 110 via conduit 142 (as shown in FIG. 1). As more CO₂ becomes available from gasifier 134 within conduit 142, high pressure nitrogen is progressively replaced with recycled sour CO₂ as the high pressure conveying gas. The high pressure nitrogen then becomes available for use as a clean fuel gas diluent in the combustion turbine combustor 136. However, until such a time as the full amount of high pressure nitrogen diluent becomes available at combustor 136, water or steam may be used as a temporary, substitute diluent in the combustor.

Following startup, and in the exemplary embodiment, unconverted carbon, i.e. char, along with fine slag begins to accumulate in the gasification plant 114 char and fines handling section 156. The char and fines are recovered in handling section 156 as a dilute slurry. The slurry is then channeled to the slag additive handling system 152. As this slurry of char and fines becomes available for recycle to the feed system 110, the fresh water makeup 424 to mix tank 406 is progressively replaced by this char and fines slurry until all of the char is being recycled to gasifier 134. The final, total amount of water fed to gasifier 134 is controlled by adjusting the slurry concentration of the char and fines slurry and/or the amount of fresh water makeup added to mix tank 406. If it is desired to add additional sour CO₂ gas to the gasifier following startup, this may be accomplished by opening block valve 397 on conduit 384.

In an alternative embodiment, high pressure nitrogen from the air separation unit 112 may not be available for use as conveying gas during gasifier startup. In this embodiment, compressed natural gas 267 may be used instead of the high pressure nitrogen. Natural gas may be used as a backup fuel for combustion turbine 192 and sufficient quantities may be available for use as a high pressure conveying gas in place of the high pressure nitrogen. In this embodiment, coal is ground, dried and loaded into the main coal silo 240 and solids pump storage bin 338. High pressure natural gas is then heated in heater 258 and channeled via conduits 144, 360, 362, 364, 366, 388, and 398 to a plant flare (not shown). During startup, this allows the natural gas flow rate to be stabilized at the desired value. Gasifier 134 may then be started using natural gas without the use of any coal solids, since natural gas is a suitable fuel for the gasifier all by itself. Since natural gas has no ash for which a slag modifier is required, the gasifier can be started up on natural gas without having to start the slag additive system 152.

In this embodiment, gasifier 134 is started on natural gas by substantially simultaneously closing block valve 399 in conduit 398 and opening block valve 396 in conduit 380. Oxygen is then channeled into gasifier 134 through conduit 323. Thermal energy stored in the gasifier refractory initiates the reactions, and syngas generation begins, as described in more detail herein. In this embodiment, gasifier 134 may operate with natural gas as the sole feed for any practical duration of time.

In this alternative embodiment, the introduction of solid particulate fuel begins by activating the solids pumps 340. Coal particles from the discharge of pumps 340 drop into the solids pickup conduit 360 wherein the coal is entrained by the flow of natural gas to gasifier feed injector 348 via conduit 380, as described in more detail herein. The addition of coal to the natural gas substantially increases the flow of fuel to gasifier 134, and a flow rate of oxygen to the gasifier must be increased in order to provide an adequate amount of oxygen to gasify all of the carbon in the feed. The slag additive slurry must also be started up so that slag additive slurry can be fed to the gasifier by closing block valve 426 on conduit 428 and opening block valve 430 on conduit 422. Gasifier 134 may run on this mixture of natural gas and coal for any practical duration of time. During operation, the natural gas and coal flow rates may not exceed the downstream demand for syngas. More specifically, gasifier 134 may be started up with a low flow rate of natural gas so that, when the coal particles are added, an amount of syngas is produced that satisfies the downstream process demand. Alternatively, if the gasifier operations have already been established at a higher than desirable rate for the transition to coal feed, the natural gas flow may be reduced, together with an appropriate modification of the oxygen flow rate, to allow the introduction of coal particles into the natural gas. As syngas production continues in the gasifier, CO₂ may be recovered from the syngas, compressed and routed to conveying gas heater 258 to progressively replace the natural gas. As the composition of the conveying gas transitions from 100% natural gas to 100% recycled sour CO₂, the flow rate of solids into the solids pickup conduit 360 is increased to maintain substantially the same level of fuel energy flow into gasifier 134. The flow rate of slag additive/recycle char and fines slurry is also increased to match the increasing flow rate of coal. Using natural gas during startup operations allows gasifier 134 to be started up using a clean, sulfur-free fuel, which is therefore advantageous for IGCC plants located in regions with process gas flaring restrictions.

FIG. 5 is a process flow diagram of an alternative solids recycle configuration for a gasifier startup system 500 used with pressurization and conveyance section 124 shown in FIG. 3. Specifically, FIG. 5 illustrates a configuration that enables the use of a non-ventable carrier gas during an exemplary startup sequence, such as but not limited to a sour CO₂-rich carrier gas. “Non-ventable carrier gas” as used herein is a gas that may be suitable for use as a carrier gas for the gasification process, but preferably used within only a limited portion of the feed system 110 because of, for example, the potential for equipment corrosion, potential undesirable mixing with or contamination of other gases used within and/or in communication with feed system 110, and/or preferably not vented to atmosphere without first undergoing some form of treatment, such as, for example, contaminant removal or chemical conversion.

In the illustrated embodiment, solids pumps 340 discharge a flow of solid fuel particles via conduit 352 into a stream 362 of non-ventable carrier gas that creates a startup fuel that includes solid fuel particles in non-ventable carrier gas. Carrier gas is substantially prevented from leaking back through solids pumps 340 by controlling the flow rates of seal gas 354 so that the flow rates are equal to or greater than the gas leak rate through each respective solids feed pump 340. The particle—gas mixture is channeled through a common startup line 502 and through a non-ventable carrier gas startup line 504. In the illustrated embodiment, a pressure letdown orifice (PLO) 506 is positioned along line 504 that reduces the pressure generated by a non-ventable carrier gas compressor (not shown) and solids pump 340 so that downstream equipment, such as for example cyclone 520 and feed recycle and purge bin 522, may not need to be designed to handle high pressure, while also ensuring that the flow of the particulate/gas mixture is minimally disturbed when the particulate/gas mixture is diverted to the gasifier injector 348 during startup. Alternatively, an adjustable pressure letdown device may be used in place of PLO 506. Additionally, and in a further alternative embodiment, multiple pressure letdown devices may be coupled to one another in series in order to distribute the required pressure drop across several devices so that equipment wear may be substantially minimized, wherein the pressure letdown devices may be any type of pressure reducing interfaces that enable feed system 110 to be operated as described herein.

In the illustrated embodiment, a cyclone 520 is positioned upstream from a feed recycle and purge bin 522 and separates a substantial portion of the solids from the non-ventable carrier gas and channels the solids into the feed recycle and purge bin 522. Moreover, finely ground coal within an overhead flow 524 from cyclone 520 is channeled through a secondary cyclone 526 that returns the coal fines back to feed recycle and purge bin 522 via a conduit 528. Very fine particle removal is accomplished using a filtering device 530, such as for example a barrier filter, that is positioned downstream of secondary cyclone 526. Excess gas from secondary cyclone 526 is channeled to filter 530 via conduit 532 where, along with the other purges from the system, the combined gas is filtered to remove substantially all remaining coal dust.

During operations and in the exemplary embodiment, gas is periodically blown back to release accumulated solids material from filtering device 530. The accumulated material is channeled through a rotating valve to meter the material, as well as delump any agglomerations that remain following release from filtering device 530. The material is then channeled into the filter bottoms discharge line 536 and into the feed recycle and purge bin 522. The particle free non-ventable gas leaving filtering device 530 is channeled via conduit 538 to a gas treatment system (not shown) to remove contaminates therefrom, and/or a flare (not shown) for disposal, or may be recycled to the sour CO₂-rich gas storage drum (not shown) for recompression and reuse. In an alternative embodiment, any combination of particulate matter/gas separation and collection devices may be used that facilitate separating the particulate matter from the non-ventable gas as described herein, including subsequent collection of such particulate matter for recycle within the system or disposal.

In the illustrated embodiment, the separated solid particles in feed recycle and purge bin 522 may have residual non-ventable gas remaining in the particles and interstitial spaces between the particles. To further remove residual sour CO₂-rich gas, a stream of N₂ stripping gas is channeled via conduit 540 into a bottom portion 542 of bin 522. During operations, the stripping gas may both fluidize the solids in the bottom outlet of the bin to facilitate providing a flow rate of the solids through an exit of bin 522, and facilitates purging the residual non-ventable carrier gas as the gas rises through bin 522. A mixture of N₂ and residual non-ventable carrier gas exits a top portion 544 of feed recycle and purge bin 522 and is channeled, as needed, to a gas treatment unit and/or flare (both not shown) via conduit 545 for handling prior to discharge. Alternatively, conduit 545 may be joined in combination with conduit 538 upstream or downstream from the gas treatment system (not shown) and/or the flare. Solid fuel particles that are substantially free of residual non-ventable gas exit feed recycle and purge bin 522 are metered from bin 522 by a rotating valve 546, or alternate metering device, into a flowing stream of low pressure N₂ conveying gas within conduit 548. The low pressure N₂ conveying gas within conduit 548 transports the non-ventable gas-free separated solids back into the solids pump feed bin 338 via conduit 550 for reuse. A breather line 552 is also provided on the top of the solids pump feed bin to allow the LP N₂ transport gas to escape back into the LP N₂ cleanup system, as described in detail herein. During gasifier startup operations, the startup mixture is diverted from the non-ventable carrier gas startup line 504 to the gasifier feed injector 348. In an alternate embodiment, the stripping gas is used to facilitate the purging of the residual non-ventable carrier gas from the solids, and the flow of solids out of bin 522 is facilitated by other techniques, such as but not limited to mechanical vibration. In another alternate embodiment, at least a portion of the stripping gas is mixed and purges the solids discharging from bin 522 via the metering device

In the exemplary configuration of a gasifier startup system 500 shown in FIG. 5 and in an alternative embodiment, the transfer of solids from the feed recycle bin 522 may be configured to operate in a batch mode, whereby, for example, solids may be transferred from the feed recycle bin 522 to the solids pump feed bin 338 after the gasifier startup system 500 has been sufficiently depressurized. For example, feed recycle and purge bin 522 may be positioned directly above solids pump feed bin 338 in such a way as to allow solids passing through metering valve 546 to drop directly down into feed recycle and purge bin 522 after the recycle portion of the system has been sufficiently depressurized. In another alternative embodiment, pressurization and conveyance section 124 may be operated in a semi-batch mode by installing a lockhopper (not shown) between the feed recycle bin 522 and the solids pump feed bin 338. In still another alternative embodiment, pressurization and conveyance section 124 may be configured to operate in a continuous mode by installing one or more pressure let down pumps (not shown) or the equivalent between the feed recycle bin 522 and the solids pump feed bin 338. In another alternative embodiment, the solids may be conveyed from feed recycle bin 522 by any technique, such as but not limited to mechanical conveyance, such that feed system 110 functions as described herein.

The use of a feed system such as the one described above allows the use of a non-ventable carrier gas during gasifier startup because of the active separation that it creates between the non-ventable gas and the rest of the feed system. This active separation occurs at two places within the system, at the point where solids are added to the non-ventable gas at the fuel mixture assembly point and at the point where the solids are removed from the non-ventable gas at the fuel mixture disassembly point. The first location, the fuel mixture assembly point, is between the discharge of the solids pump and the mixing point where the startup fuel mixture is assembled by mixing solid particulate fuel with a flow of non-ventable carrier gas. A flow of seal gas introduced into this first location at a flow rate equal to or greater than the leak rate of gas back through the solids pump prevents the non-ventable gas from leaking backwards through the solids pump and entering the upstream part of the feed system. The second location, the fuel mixture disassembly point, is located on the startup conduit where the fuel mixture is disassembled during the period when a steady flow of the fuel mixture is being established just prior to startup. By separating the solids from the non-ventable gas, including stripping out all residual gas from among the particles, the non-ventable carrier gas is prevented from entering the upstream portion of the feed system along with the solid fuel particles that are returned to the solids feed bin for later reuse.

FIG. 6 is a process flow diagram of an alternative solids recycle configuration for a gasifier startup system 600 used with pressurization and conveyance section 124 shown in FIG. 3. In the illustrated embodiment, system 600 is substantially similar to system 500 shown in FIG. 5. However, feed recycle and purge bin 522, shown in FIG. 5, is replaced with a sour CO₂ stripping column 602. Solid fuel particles removed from the non-ventable carrier gas are channeled into stripping column 602 where the solid fuel particles encounter an upward moving flow of N₂ stripping gas. The N₂ stripping gas purges the residual non-ventable carrier gas as the stripping gas rises through column 602. Because of the smaller size of column 602, the flow of N₂ stripping gas passing through column 602 may be substantially less than the flow of N₂ stripping gas required to operate the feed recycle and purge bin 522. A mixture of N₂ and residual carrier gas exits a top 604 of column 602 and is channeled, as needed, to a gas treatment unit and/or to a flare (both not shown) via a conduit 606 for handling prior to discharge. Solid fuel particles that are substantially free of residual non-ventable gas exit a bottom 608 of stripping column 602 where the solid fuel particles are metered through a rotating valve 610 and are channeled via conduit 612 into the solids pump feed bin 338. During operations, this system provides solids separation and stripping equipment that is small enough to be installed above the solids pump feed bin 338. Although stripping column 602 is shown as a featureless column, in the exemplary embodiment, stripping column 602 may be constructed with a plurality of downward sloping interior baffles to facilitate channeling the solids in a zigzag pattern as the particles descend through stripping tube, thus enhancing contact with the stripping gas, and facilitate further removal of non-ventable gas from the solid fuel particles. Alternatively, stripping column 602 may have any form of internal configuration and gas and solids distribution devices that facilitate such non-ventable gas removal. Further, although a rotating valve 610 is shown connected to the bottom of stripping column 602, any device suitable for controlling a flowrate of particles via line 612 may be used herein.

Alternatively, the equipment in the exemplary configuration shown in FIG. 6 can be configured to operate at high pressure, and pressure letdown orifice device 506 may be eliminated or adjusted to allow the equipment to operate at the desired higher pressure. In this alternative configuration, N₂ stripping column 602 operates as a pressurized column. A surge bin may be coupled to bottom 608 of column 602 such that solids may be stored at high pressure until controlled depressurization of the solids from the surge bin to the solids pump feed bin 338 may occur. As a further alternative, the surge bin may be replaced by a lock hopper or an adjustable pressure letdown device similar to 506 or any other suitable device or system whereby the solids from the bottom 608 of pressurized column 602 may be depressurized and conveyed in a controlled manner from column 602 to solids pump feed bin 338.

FIG. 7 is a process flow diagram of an alternative solids recycle configuration for a gasifier startup system 700 used with pressurization and conveyance section 124 shown in FIG. 3. In the illustrated embodiment, system 700 is substantially similar to system 500 shown in FIG. 5. However, feed recycle and purge bin 522, shown in FIG. 5, is replaced with a solids transport system 702. In the illustrated embodiment, transport system 702 includes a feed recycle bin 704 coupled in flow communication with a solids pump feed vessel 706 that is positioned upstream from a plurality of solids pumps, similar to solids pump 340 shown in FIG. 3 and described in more detail herein. In the illustrated embodiment, transport system includes a first solids pump 708 and a second solids pump 710.

In the illustrated embodiment, solids that are separated from the startup carrier gas as described herein are channeled to feed recycle bin 704 via conduit 712. Solids are channeled via conduit 714 to the solids pump feed vessel 706 and into a suction end 716 of solids pump 708 via conduit 718. Solids pump 708 discharges the solid material into a suction end 720 of the solids pump 710 via conduit 722, which delivers carrier gas-free particles to solids pump feed bin 322 via conduit 724.

During operations, the removal of the residual non-ventable carrier gas from the interstitial spaces among the separated solid fuel particles is accomplished in solids pump 708. A small flow 726 of seal N₂ is injected into conduit 722 and the seal N₂ moves upstream through the solids in pump 708, and strips away substantially all of the residual non-ventable carrier gas and prevents any residual carrier gas from passing through the pump. Solids pump 710 is used to create a sealed, slightly pressurized space between the two pumps 708 and 710 into which the seal N₂ can be injected. Such a configuration forces N₂ upstream through pump 708 while producing stripped solids as the solids pass through solids pumps 708 and 710. The seal N₂ that moves upstream through pump 708 passes up through the solids pump feed vessel 706 and feed recycle bin 704 and, along with the removed non-ventable gas, is channeled, as needed, to a gas treatment unit and/or to a flare (both not shown) via a conduit 728 for handling prior to discharge, as described in more detail herein. Such a configuration enables the flow requirement for stripping nitrogen to be significantly reduced when compared with the configurations shown in FIGS. 5 and 6. In an alternative embodiment, a purge gas may be injected and distributed into solids pump 708 and/or solids pump 710. In a further alternative embodiment, nitrogen may be injected immediately upstream of solids pump 708. In another alternative embodiment, one or more of solids pump 708 and solids pump 710 are high pressure solids pumps. In another alternative embodiment, a surge vessel may be coupled in flow communication between solids pump 708 and solids pump 710. Alternatively, the transport system may include any number of solids pumps, such as for example a single solids pump 708, that enables pressurization and conveyance section 124 to function as described herein. Alternatively, the seal nitrogen described herein may be any clean, inert gas that enables the fuel and gasification systems to function as described herein.

As shown in FIGS. 5, 6 and 7 and described herein, the carrier gas used during startup operations is non-ventable gas, such as sour CO₂-rich gas. However, such embodiments also may be used with other gases, such as but not limited to sweet CO₂-rich gas. Such CO₂ rich gases may be recovered from the syngas produced in the gasifier. As described herein, the CO₂-rich gas may be withdrawn from a number of different sources including, but not limited to: a storage vessel previously filled with a gas recovered from an earlier operation of the gasifier, an additional gasifier train operating in parallel with the gasifier train being started, an underground cavern and/or reservoir previously filled with gas recovered from an earlier operation of the gasifier, a pipeline connected to a suitable source of the gas, and a CO₂-rich gas generator such as a combustion device capable of producing water-free CO₂-rich gas, wherein such a combustion device may be coupled to a condenser and knockout system to remove undesirable quantities of water from the CO₂-rich products of combustion. Alternatively, syngas may be used as the non-ventable carrier gas.

Described herein is a fuel feed system that may be utilized in IGCC plants that provides a cost-effective, highly efficient and reliable system for supplying coal to an IGCC plant by integrating coal grinding, moisture control and a solids pump upstream of a gasifier. In each embodiment, the fuel preparation system controls the moisture being channeled to the gasifier to a desired level that is between the moisture content in a dry feed system and the moisture content in a slurry feed system. More specifically, a pulverized PRB coal feed having a well-controlled internal moisture content may be tailored to optimize not only the gasifier performance, but also the performance of the overall system in which the gasifier plays a central role. Further, in each embodiment, the addition of the solids pump upstream of the gasifier facilitates pressurizing the coal from atmospheric pressure at the pump inlet to a pressure above the gasifier operating pressure in order to facilitate pneumatic conveyance of the coal into the gasifier. As a result, a continuous flow of pressurized coal is channeled to the gasifier. Moreover, an improved feed system is disclosed that provides an alternative to conventional dry feed systems for feeding low rank coals, such as sub bituminous coals and lignites, to a refractory-lined, entrained-flow gasifier for the production of syngas for power generation in an IGCC plant. As such, a simpler, more robust method of providing a feed system that is similar to slurry feed systems is disclosed that replaces the expensive lock hoppers, valves and compressors with an alternative method of pressurizing the solids used therein. Accordingly, the costs associated with maintaining a dry feed system and the inefficiencies associated with a slurry feed system are both avoided.

Exemplary embodiments of fuel feed systems are described above in detail. The fuel feed system components illustrated are not limited to the specific embodiments described herein, but rather, components of each system may be utilized independently and separately from other components described herein. For example, the fuel system components described above may also be used in combination with different fuel system components.

As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

1. A method of startup for a gasification system including a gasifier, said method comprising: assembling a fuel mixture for use by the gasifier at a fuel mixture assembly point, the fuel mixture including a quantity of particulate solid fuel and a quantity of non-ventable carrier gas; channeling the fuel mixture through a first conduit to a fuel mixture disassembly system including a non-ventable carrier gas removal apparatus; establishing a substantially steady flow of the fuel mixture within the first conduit; and redirecting the fuel mixture through a second conduit to the gasifier to facilitate gasifier startup.
 2. A method in accordance with claim 1, further comprising disassembling the quantity of particulate solid fuel from the quantity of non-ventable carrier gas using the non-ventable carrier gas removal apparatus.
 3. A method in accordance with claim 2, wherein disassembling the quantity of particulate solid fuel from the quantity of non-ventable carrier gas further comprises: channeling the disassembled quantity of non-ventable carrier gas to at least one of a storage device, a recycle device and a disposal device; and recycling the disassembled quantity of particulate solid fuel to at least one of a particulate solid fuel storage device and a disposal device.
 4. A method in accordance with claim 1, further comprising obtaining the non-recyclable carrier gas from at least one of: a storage vessel containing a quantity of previously produced non-ventable carrier gas; a pipeline connected to a source of non-ventable carrier gas; an underground cavern or reservoir containing a quantity of non-ventable carrier gas; a gas generating apparatus capable of generating a quantity of non-ventable carrier gas; and a second gasifier train operating in parallel with the gasifier.
 5. A method in accordance with claim 1, wherein establishing a substantially steady flow of the fuel mixture further comprises forming an active gas separation within the non-ventable carrier gas removal apparatus to facilitate producing the quantity of particulate fuel solids substantially free from the non-ventable carrier gas.
 6. A method in accordance with claim 5, further comprising forming a gas seal upstream of the fuel mixture assembly point to facilitate preventing a backflow of non-ventable carrier gas into a source of the particulate solid fuel.
 7. A method in accordance with claim 1, wherein channeling the fuel mixture through a first conduit further comprises channeling the fuel mixture through at least one of a feed recycle bin and a stripping apparatus.
 8. A gasification system comprising: a gasifier; a fuel mixture for use by said gasifier, wherein said fuel mixture comprises a quantity of particulate solid fuel and a quantity of non-ventable carrier gas; and a pressurization and conveyance section coupled in flow communication upstream from said gasifier; said pressurization and conveyance section comprising a fuel mixture disassembly system including a non-ventable carrier gas removal apparatus configured to strip the quantity of non-ventable carrier gas from the fuel mixture.
 9. A system in accordance with claim 8, wherein said pressurization and conveyance section is configured to channel a stream of stripping gas against a flow of the fuel mixture to facilitate separating the quantity of non-ventable carrier gas from the quantity of particulate solid fuel.
 10. A system in accordance with claim 8, wherein said pressurization and conveyance section comprises at least one solids pump positioned downstream from the at least one of a feed recycle bin and a stripping column, the solids pump configured to facilitate reducing an amount of stripping gas required to separate the carrier gas from the quantity of the particulate solid.
 11. A system in accordance with claim 10, wherein said pressurization and conveyance section system is further configured to channel the flow of the fuel mixture through at least one of a feed recycle bin and a stripping apparatus.
 12. A system in accordance with claim 8, wherein said non-ventable carrier gas comprises one of sour CO₂, sweet CO₂, or synthesis gas.
 13. A system in accordance with claim 8, wherein said pressurization and conveyance section further comprises a pressure regulation apparatus positioned upstream from said fuel mixture disassembly system and configured to reduce a pressure of a fuel mixture before the fuel mixture is channeled to said fuel disassembly system.
 14. A system in accordance with claim 8, further comprising a conduit coupled in flow communication downstream from said pressurization and conveyance section, said conduit configured to channel a flow of stripping gas against the flow of the fuel mixture to further facilitate separating the non-ventable carrier gas from the quantity of fuel.
 15. A fuel feed system for use in a gasification system including a gasifier, said fuel feed system configured to channel a fuel mixture to the gasifier, wherein said fuel mixture comprises a quantity of particulate solid fuel and a quantity of non-ventable carrier gas, said fuel feed system comprising a pressurization and conveyance section coupled in flow communication upstream from the gasifier, said pressurization and conveyance section comprising a fuel mixture disassembly system including a non-ventable carrier gas removal apparatus configured to strip a quantity of non-ventable carrier gas from a quantity of particulate solid fuel.
 16. A system in accordance with claim 15, wherein said pressurization and conveyance section is configured to channel a stream of stripping gas against a flow of the fuel mixture to facilitate separating the quantity of non-ventable carrier gas from the quantity of particulate solid fuel.
 17. A fuel feed system in accordance with claim 16, wherein said pressurization and conveyance section comprises at least one solids pump, the solids pump configured to facilitate reducing an amount of the stripping gas required to separate the quantity of carrier gas from the quantity of particulate solid fuel.
 18. A system in accordance with claim 17, wherein said pressurization and conveyance section system is further configured to channel the flow of fuel mixture through at least one of a feed recycle bin and a stripping apparatus.
 19. A system in accordance with claim 15, wherein said pressurization and conveyance section further comprises a pressure regulation apparatus positioned upstream from said fuel mixture disassembly system and configured to reduce a pressure of the fuel mixture before the fuel mixture is channeled to said fuel mixture disassembly system.
 20. A system in accordance with claim 15, further comprising a conduit coupled in flow communication downstream from said pressurization and conveyance section, said conduit configured to channel a flow of stripping gas against the flow of the fuel mixture to further facilitate separating the non-ventable carrier gas from the quantity of fuel. 